Service Manual 26 Self Trimming Export Fireplace with 3 Stage On/Off Remote

Transcription

1 Service Manual 26 Self Trimming Export Fireplace with 3 Stage On/Off Remote Model Numbers: DF2608-EU - MOD / to A DF2608-AU - MOD / Dimplex North America Limited 1367 Industrial Road Cambridge ON Canada N1R 7G REV PCN DATE Aug 6, 09 In keeping with our policy of continuous product development, we reserve the right to make changes without notice rev00

2 Table Of Contents Page 3 Page 5 Page 6 Page 7 Page 7 Page 8 Page 8 Page 9 Page 9 Page 10 Page 10 Page 11 Page 12 Page 12 Page 13 Page 14 Operation Exploded Parts Diagram and Parts List - DF2608-EU/AU Wiring Diagram and Schematic - DF2608-EU/AU Front Glass Replacement Light Bulb Replacement Mirror Replacement Main On/Off Switch Replacement Flame/Heat Selection Switch Replacement Light Dimmer Replacement Flame Action Control Replacement Flicker Motor/Flicker Rod Replacement Thermostat Control Replacement Remote Control Board Replacement Log Driver Control Board Replacement Heater Assembly Replacement Power Cord Replacement 2

3 Operation This section will explain the function of each convenient control (Figure 2). To access the controls, flip open the control panel cover towards the bottom of the fireplace (Figure 1). Figure 1 Resetting the Temperature Cutoff Switch This unit is equipped with a thermostat which controls the temperature of the room by turning the heater on and off. The heater is protected with a safety device to prevent overheating. Should the heater overheat, an automatic cut out will turn the heater off and it will not come back on without being reset. It can be reset by switching the Main ON/OFF Switch to OFF and waiting five (5) minutes before switching the unit back on. CAUTION: If you need to continuously reset the heater, unplug the unit and call customer service. Please have your model and serial number ready when calling. Figure 2 F A B E C D Remote Control The fireplace is supplied with a radio frequency remote control. This remote control has a range of approximately m, it does not have to be pointed at the fireplace and can pass through most obstacles (including walls). It is supplied with one of hundreds of independent frequencies to prevent interference with other units. The frequency designation is indicated on the back of the transmitter. A. Flame Action Control Turn the flame action control knob to adjust the flame speed to the desired level. B. Interior Light Control Turn the interior light control knob to increase or decrease the brightness of the interior light. C. LED Indicators Indicates the current function of the fireplace. D. Flame/Heat Selection Switch Toggles between flame effect, low and high heat settings. E. Heater Thermostat Control To adjust the temperature to your individual requirements, turn the thermostat control clockwise all the way to turn on the heater. When the room reaches the desired temperature, turn the thermostat knob counter clockwise until you hear a click. Leave in this position to maintain the room temperature at its setting. For additional heat, turn clockwise until you hear the click again and the heater will turn on. To turn the heater off, rotate the knob fully counter clockwise. F. Main ON/OFF Switch The Main ON/OFF Switch supplies power to all fireplace functions. Remote Control Initialization Follow steps 1 through 4 to initialization your fireplace for the first time. This procedure is also required every time there is a loss of power to the remote control in the fireplace (i.e. power failure, breaker tripped, main power switch is turned off). 1. Ensure that power is supplied to Figure 3 the intended electrical receptacle. 2. Locate manual controls (refer to Figure 2). 3. Plug in fireplace, first indicator light will flash (Figure 2C). 4. Press and hold the Flame/Heat Selection Switch (Figure 2D) for five (5) seconds ( position) UNTIL the second red indicator light flashes. 5. Press ON button located on the Battery Cover remote control transmitter (Figure 3). This will synchronize the remote control transmitter and receiver. Remote Control Usage The remote control operates the fireplace levels sequentially, flames only to flames and low heat, to flames and high heat. The level is increased every time the ON button on the transmitter is pressed. The fireplace can be turned off at any point by pressing the OFF button on the remote control transmitter. Level : The flame effect is turned on and the first red indicator light flashes momentarily. 3

4 Level : The flame effect remains on, the heater is activated to the low heat setting, and the first and second red indicator lights flash momentarily. Level : The flame effect remains on, the heater is set to the high heat setting, and all three red indicators flash momentarily. Battery Replacement To replace the battery: 1. Slide battery cover open on the hand held transmitter (Figure 3). 2. Correctly install one (1) 12 Volt (A23) battery in the battery holder. 3. Close the battery cover. 4

5 Exploded Parts Diagram - DF2608-EU/AU Replacement Parts List DF2608-EU Part Number Replacement Parts: 1. Log set RP 2. Log set Driver RP 3. Flicker Motor RP 4. Heater Assembly (w/cutout) RP 5. Thermostat RP* 6. Main On/Off Switch RP 7. Flame Action Control RP 8. Light Dimmer Control RP 9. Cord Set (DF2608-EU) RP Cord Set (DF2608-AU) RP DF2608-AU Part Number Moulded Lamp Holder RP 11. Mirror with brick effect RP 12. Front Glass RP 13. Control Knob (3 on unit) RP 14. Remote Transmitter RP 15. Remote Receiver RP 16. Remote Daughter Board RP 17. Terminal Block RP 18. Flicker Rod RP 5

6 Wiring Diagram - DF2608-EU/AU Thermostat Heater Assembly Flicker Motor Light Dimmer Control Flame Speed Control Remote Daughter Board Remote Control Receiver Cord Set Log Set Driver Main On/Off Switch 6

7 Front Glass Replacement If unit was operating prior to servicing allow at least 10 minutes for light bulbs and heating element to cool off to Replacement Procedure 1. Slide fireplace out of mantel. 2. Lay unit on it s back for safe removal of front glass. 3. Remove four (4) Phillips screws from right side of trim. 4. Remove trim. 5. Slide glass to the right side of the fireplace to remove (Figure 4). 6. Reassemble using replacement Front Glass in reverse order as described above. CAUTION: Even though the glass is safety glass it may break if bumped, struck or dropped. Care must be taken when handling the glass. Figure 4 Upper Bulb Requirements: A quantity of two (2) chandelier or candelabra bulbs with an E-14 (small) socket base, 25 Watt rating are required. Do Not Exceed 25 Watts Per Bulb Figure 5 Loosen Tighten Removing and Replacing Bulb While Holding Socket Upper Bulb Replacement Procedure 1. Slide fireplace out of mantel. 2. Lay unit on it s back for safe removal of front glass. 3. Remove four (4) Phillips screws from right side of trim. 4. Remove trim. 5. Slide glass to the right side of the fireplace to remove (Figure 4). Upper Bulbs (x2) Lower Bulbs (x3) Trim CAUTION: Even though the glass is safety glass it may break if bumped, struck of dropped. Care must be taken when handling the glass. 4. The upper bulbs are located in each corner of the upper part of the fireplace as shown in Figure Replace bulb(s) that require replacement, holding onto the light socket while unscrewing the bulb (Figure 5). 6. Reassemble in the reverse order as above. Log set Front Glass Light Bulb Replacement If unit was operating prior to servicing allow at least 10 minutes for light bulbs and heating element to cool off to Light bulbs need to be replaced when you notice a dark section of the flame or when the clarity and detail of the log exterior disappears. There are two bulbs at the top of the opening that illuminate the log set exterior and three bulbs under the log set which generate the flames and embers. It is a good idea to replace all of the light bulbs at one time if they are close to the end of their rated life. Group replacement will reduce the number of times you need to open the unit to replace the light bulbs. Lower Bulb Requirements: A quantity of three (3) chandelier or candelabra bulbs with an E-14 socket base, 60 Watt rating are required. Do Not Exceed 60 Watts Per Bulb Lower Bulb Replacement Procedure 1. Slide fireplace out of mantel. 2. Lay unit on it s back for safe removal of front glass. 3. Remove four (4) Phillips screws from the right side of trim. 4. Slide glass to right side of fireplace to remove (Figure 5). CAUTION: Even though the glass is safety glass it may break if bumped, struck of dropped. Care must be taken when handling the glass. 5. Pull the front edge of the plastic ember bed or plastic grate up and forward until the rear tab releases from the ledge located at the bottom of the mirror.! IMPORTANT: Only handle the log set by the ember bed. 7

8 ! NOTE: Log set fits tightly into firebox, some force may be necessary to remove. 6. Disconnect LED harness. 7. Set log set in front of fireplace. 8. Remove flicker rod by sliding flicker rod to the left away from the flicker motor and lift out. 9. Remove light filter bracket (the metal bracket will have a tinted film adhered to it) for easier access to light bulbs. Four (4) Philips screws hold the bracket in place (two (2) per side). 10. Unscrew bulbs counter clockwise. 11. Insert new bulbs. 12. Replace light filter bracket and flicker rod. 13. Re-connect LED harness. 14. Replace the log set by inserting the front edge of the fireplace and push down on the rear edge of the ember bed until it snaps into place. 15. Lay unit on it s back and slide front glass back into position and attach trim. Mirror Replacement Replacement Procedure 1. Slide fireplace out of mantel. 2. Lay unit on it s back for safe removal of front glass. 3. Remove four (4) Phillips screws from the right side of trim. 4. Slide glass to right side of fireplace to remove (Figure 5, page 7). CAUTION: Even though the glass is safety glass it may break if bumped, struck of dropped. Care must be taken when handling the glass. 5. Pull the front edge of the plastic ember bed or plastic grate up and forward until the rear tab releases from the ledge located at the bottom of the mirror. Figure 6 Clamp 9. Tighten clamps back into place and reassemble fireplace in reverse order as described above. Main On/Off Switch Replacement Replacement Procedure: if it is laying on its back), four (4) screws in the front directly under the control panel; and two (2) screws on the bottom of the fireplace (see Figure 7). The bottom panel is now free to be removed. Figure 7 Screws To Remove Mirror! IMPORTANT: Only handle the log set by the ember bed.! NOTE: Log set fits tightly into firebox, some force may be necessary to remove. 6. Loosen but do not remove the two (2) Philips screws that clamp the mirror in place, and swivel down so that the clamp clears the edge of the mirror (Figure 6). 7. Push the mirror up from underneath to clear the frame and remove. 8. Insert replacement mirror top end first and lay the bottom end gently in the bottom track of the frame. 4. Locate the Main On/Off Switch mounted on the control panel on the left side (Figure 8, Page 9) and disconnect the two (2) wiring clips noting their original locations. 8

9 Figure 8 Main ON/OFF Switch Figure 9 Mounting Studs (2) Flame/Heat Selection On/Off Switch Retainer Clips (one top, one bottom) 5. Depress the two (2) retainer clips on the top and bottom of the switch and push the switch out of the cover. 6. Properly orientate the new switch and re-connect all of the wiring clips and connections as before. 7. Reassemble in the reverse order as above. Flame/Heat Selection Switch Replacement Replacement Procedure the bottom of the fireplace (see Figure 7, page 8). The 4. Locate the Flame/Heat Selection Switch mounted on the control panel on the right side (Figure 9) and disconnect the wire harness that leads to the Remote Control Receiver. 5. The Flame/Heat Selection Switch is fastened to the control panel by two (2) mounting studs, one on either side of the switches. Either squeeze each mounting stud s clasp to release, or use side cutters to cut and remove each of the two (2) mounting studs on the switch.! NOTE: If mounting studs are cut, replacement mounting studs will need to be inserted from the outside surface of the control panel. 6. Properly orientate the new switch and snap into place onto the mounting studs. 7. Reconnect the wire harness. 8. Reassemble in the reverse order as above. Wire Harness to Remote Board Light Dimmer Replacement Replacement Procedure: the bottom of the fireplace (see Figure 7, page 8). The 4. Locate the Light Dimmer Control Board mounted on the left side (Figure 10, page 10). 5. Disconnect the two (2) wire leads from the control board s left hand side, noting their original locations. 6. Pull off the Light Dimmer Control knob and unscrew the retaining nut (Figure 10, page 10). The potentiometer can now be removed from the panel by pushing the potentiometer through the front of the panel and removed from inside the cabinet. 7. The Light Dimmer Control board is fastened to the underside of the ember bed support by four (4) tmounting studs, one in each corner (Figure 10, page 10). Either squeeze each mounting stud s clasp to release, or use side cutters to cut and remove each of the four corner mounting studs on the board. 9

10 Figure 10 Figure 11 Retaining Nut Potentiometer Retaining Nut Potentiometer Light Dimmer Control Board Mounting Studs (4)! NOTE: If mounting studs are cut, replacement mounting studs will need to be inserted from underneath ember bed. Follow steps 1-5 of Mirror Replacement procedure on Page 8 to do this. It is recommended to attempt to release the control board without cutting mounting studs. 8. Clear both ends of each cut mounting stud from the control board and the support panel - new mounting studs are supplied with the replacement part. 9. Properly orientate the new potentiometer and control board and re-connect all of the wiring connections. 10. Reassemble in the reverse order as above. Flame Action Control Replacement Replacement Procedure: the bottom of the fireplace (see Figure 7, Page 8). The 4. Locate the Flame Action Control mounted on the left hand side (Figure 11). 5. Remove the white and blue wire leads from the bottom, left corner of the control board and feed the wires underneath the Flame Action and Light Dimmer Control boards as shown in Figure 11. Flame Action Control Board Mounting Studs (4) 6. Pull off the Flame Action Control knob and unscrew the retaining nut (Figure 11). The potentiometer can now be removed from the panel by pushing the potentiometer through the front of the panel and removed from inside the cabinet. 7. The Flame Action Control board is fastened to the underside of the ember bed support by four (4) mounting studs, one in each corner (Figure 11). Either squeeze each mounting stud s clasp to release, or use side cutters to cut and remove each of the four corner mounting studs on the board.! NOTE: If mounting studs are cut, replacement mounting studs will need to be inserted from underneath ember bed. Follow steps 1-5 of Mirror Replacement procedure on Page 8 to do this. It is recommended to attempt to release the control board without cutting mounting studs. 8. Clear both ends of each cut mounting stud from the control board and the support panel - new mounting studs are supplied with the replacement part. 9. Properly orientate the new potentiometer and control board and re-connect all of the wiring connections. 10. Reassemble in the reverse order as above. Flicker Motor/Flicker Rod Replacement Replacement Procedure: 10

11 the bottom of the fireplace (see Figure 7, Page 8). The 4. Locate Flicker Rod and Flicker Motor in the base assembly (Figure 12). Figure 12 5 Colour Cable Flicker Rod 5. Gently pull the Flicker Rod to the right as far as possible into the rubber bushing (Figure 13). Flicker Motor! NOTE: When removing the Flicker Rod, damage may occur if bent excessively. If the Flicker Rod is damaged, replace to insure proper operation. 6. Cautiously bend the Flicker Rod enough so that the remaining end of the Flicker Rod clears the plastic bushing on the left (Figure 13). Figure 13 Mounting Screw 7. Remove the Flicker Rod by pulling it free from the rubber bushing on the motor shaft (Figure 13). Rubber Bushing Flicker Motor Mounting Screw 8. Before removing the Flicker Motor, cut the Flicker Motor wires (five (5) in total) close to the Flicker Motor end with wire cutters. 9. Remove the rubber bushing from the motor shaft by applying needle nose pliers to the motor shaft and twist the rubber bushing off of the motor shaft. 10. Remove the motor mounting screws and remove motor from the mounting bracket (Figure 13). 11. Discard old Flicker Motor. 12. Pick up new Flicker Motor and cut wire leads to 3 1/2 inch long with wire cutters. 13. Using one of the supplied wire connectors from the Replacement Part Kit, place one (1) yellow wire from the new Flicker Motor and the yellow wire cut in step 8 into each terminal. 14. Secure the wire connector by crimping the 3M symbol with pliers. 15. Pull on end of wires to ensure a strong connection. 16. Repeat the process for the four (4) remaining wires. ENSURE THAT ALL WIRES ARE PAIRED BY COLOUR IN EACH CONNECTOR. 17. Properly orientate and secure the replacement Flicker Motor to the bracket with screws removed in step Replace rubber bushing on motor shaft. 19. Replace Flicker Rod. 20. Reassemble firebox and replace in mantel. Thermostat Control Replacement Replacement Procedure: the bottom of the fireplace (see Figure 7, Page 8). The 4. Locate the Thermostat Control mounted on the control panel on the right hand side (Figure 14, page 12) and disconnect the two (2) wiring clips noting their original locations. 5. Pull off the thermostat control knob to expose the two (2) Philips mounting screws (Figure 14, page 12). 6. Remove the mounting screws and remove the thermostat control switch from inside the control panel. 7. Properly orientate the new Thermostat Control and reconnect the wiring connections. 8. Reassemble in the reverse order as above. 11

12 Figure 14 Figure 15 Remote Control Receiver Screw Thermostat Mounting Studs (4) Remote Control Replacement Remote Control hand held transmitters require no replacement procedure however, a reinitialization procedure may need to be followed. Refer to Page 1 for the Remote Initialization procedure. Receiver Replacement Procedure: the bottom of the fireplace (see Figure 7, Page 8). The 4. Locate the Remote Control Board mounted on the right hand side (Figure 15). 5. Remove the two (2) blue, two (2) orange and one (1) grey wire lead from the Remote Control Board as shown in Figure 15, noting their original locations. 6. The Remote Control Board is fastened to the underside of the ember bed support by four (4) mounting studs, one in each corner (Figure 15). Either squeeze each mounting stud s clasp to release, or use side cutters to cut and remove each of the four corner mounting studs on the board.! NOTE: If mounting studs are cut, replacement mounting studs will need to be inserted from underneath ember bed. Follow steps 1-5 of Mirror Replacement procedure on Page 8 to do this. It is recommended to attempt to release the control board without cutting mounting studs. 8. Clear both ends of each cut mounting stud from the control board and the support panel - new mounting studs are supplied with the replacement part. 9. Properly orientate the new control board and re-connect all of the wiring connections. 10. Reassemble in the reverse order as above. Log Driver Control Board Replacement Replacement Procedure: the bottom of the fireplace (see Figure 7, Page 8). The 4. Locate the Log Driver Control Board mounted on the right hand side (Figure 16, page 13) and disconnect the two (2) blue, two (2) orange wire leads and the LED wire harness connector, noting their original positions (refer to Figure 16). 5. The Log Driver Control Board is fastened to the underside of the ember bed support by four (4) mounting studs, one in each corner (Figure 16). Either 12

13 Figure 16 Figure 17 Screws to Remove Log Driver Control Board Mounting Studs (4) may be a snug fit inside the firebox. Orientate yourself with the placement of the Heater Assembly and wiring as shown in Figure 18. Figure 18 Top Panel Heater Assembly Heating Element Multi-Colour LED Wire Harness squeeze each mounting stud s clasp to release, or use side cutters to cut and remove each of the four corner mounting studs on the board.! NOTE: If mounting studs are cut, replacement mounting studs will need to be inserted from underneath ember bed. Follow steps 1-5 of Mirror Replacement procedure on Page 8 to do this. It is recommended to attempt to release the control board without cutting mounting studs. 6. Clear both ends of each cut mounting stud from the control board and the support panel - new mounting studs are supplied with the replacement part. 7. Properly orientate the new control board and re-connect all of the wiring connections. 8. Reassemble in the reverse order as above. Heater Assembly Replacement Replacement Procedure 2. Remove the 10 Philips screws that fasten the top cover to the rest of the firebox. There are: (four) 4 screws at the back of the firebox, along the top; two (2) screws on each side and at the top of the firebox; and two (2) screws on the top of the firebox (Figure 17). 4. Flip the top panel over and place upside down on the top of the unit. You may experience some resistance as the Heater Assembly is mounted to the top panel and Terminal Block Wires Leading to Bottom Assembly 5. Disconnect: the two (2) wire connectors on the right side of the Heater Assembly (one yellow, one black); the three (3) blue vertically stacked wire connectors attached to the left side of the heating element; and the two (2) wire connectors on the left side of the Heater Assembly (one blue and one black), noting all of their original positions. 6. Turn the top panel over and while supporting the Heater Assembly and panel in one hand, remove the five (5) heater mounting screws, noting the center screw is of a larger diameter (Figure 19). Figure Separate the Heater Assembly from the top panel. 8. Properly orientate the new Heater Assembly and re-connect all of the wiring connections. 9. Reassemble in the reverse order as above. 13

14 Power Cord Replacement Replacement Procedure: the bottom of the fireplace (see Figure 7, Page 8). The 5. Locate and disconnect the two (2) power cord wire connections: one from the middle of the three (3) connectors on the 3 Position On/Off Switch; the other on the Flame Speed Control board, noting their original locations (Figure 20). Figure 20 3 Position Switch Power Cord Wire Clamp Flame Speed Control 6. Using pliers, squeeze the sides of the plastic wire clamp from inside the bottom assembly area and push it through the chassis. 7. Release clamp from power cord and remove power cord. 8. Install replacement power cord through opening in the chassis and secure with clamp. 9. Reassemble in the reverse order as above. 14